J Fail. Anal. and Preven.
(2016) 16:95–103
DOI 10.1007/s11668-015-0050-5
TECHNICAL ARTICLE—PEER-REVIEWED
A Study to Establish Correlation Between Intercolumnar Cracks
in Slabs and Off-Center Defects in Hot-Rolled Products
Diptak Bhattacharya . T. K. Roy . Vinay V. Mahashabde
Submitted: 17 September 2015 / in revised form: 11 November 2015 / Published online: 28 December 2015
Ó ASM International 2015
Abstract Delamination and cracking related to segrega-
tions are mostly observed at the centerline of hot-rolled
products. The delamination is related to heavy concentra-
tion of manganese sulfide inclusions originating from
centerline segregation in slabs. In multiple cases, similar
delamination or cracking is observed at locations away
from the mid thickness plane of hot-rolled products during
forming operations at customer end. This leads to rejection
of materials. Metallographic investigation reveals segre-
gation line with plenty of manganese sulfide stringers at the
off-center location similar to observations in cases of
centerline defects. Centerline segregation is a well-under-
stood phenomenon, but the presence of off-center
segregation line in hot-rolled products has not been sys-
tematically studied before. Several literatures report
intercolumnar cracks in slabs to be filled with segregations.
Also, they occur away from the centerline of continuously
cast slabs. A laboratory-based experimental study was
conducted using a slab suspected by S-printing to contain
D. Bhattacharya (&)
Product Technology Flat Products, India, Tata Steel Ltd., Stage
Lab, LD3&TSCR, TATA Steel Ltd., Jamshedpur 831005,
Jharkhand, India
e-mail: diptak.bhattacharya@tatasteel.com
T. K. Roy
Product Technology Flat Products, India, Tata Steel Ltd.,
LD2&SC, TATA Steel Ltd., Jamshedpur 831005, Jharkhand,
India
e-mail: tkr@tatasteel.com
V. V. Mahashabde
Product Technology Flat Products, India, Tata Steel Ltd., Office
of Chief Technology Officer (Flat Products), TATA Steel Ltd.,
Jamshedpur 831005, Jharkhand, India
e-mail: vvmaha@tatasteel.com
intercolumnar cracks. The aim of this study was to evaluate
the effect of intercolumnar cracks on internal quality of
rolled products. This paper reports the finding of this study
that established a strong correlation between intercolumnar
cracks in slabs and off-center cracking in hot-rolled
products.
Keywords Intercolumnar cracks
Macroetching

Sulfur print
Segregation
Introduction
Internal quality of hot-rolled sheets or plates is crucial for
the sound performance of products during their forming
and final application. There have been several instances
when delamination or cracks are reported at the mid
thickness location of hot-rolled products during forming
stage as shown in Fig. 1. Metallographic investigations in
most cases reveal a segregation band of manganese sulfide
stringers along the centerline of rolled products indicating
the defect to have originated from centerline segregation in
slab.
During cold-forming operations, some customers of hot-
rolled products reported similar delamination or cracking at
locations away from the centerline (henceforth, denoted as
off-center) as shown in Fig. 2a, b, respectively. Metallo-
graphic investigations indicate a segregation line along the
off-center crack location similar to that observed to occur
on account of centerline segregation in slabs. This may be
noted from Fig. 3. Optical microscopy reveals elongated
stringers of manganese sulfide in the off-center segregation
band as shown in Fig. 4. This clearly suggests that the
segregation at the off-center location of the rolled product
leads to delamination or cracks during forming operations.
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The off-center segregation lines may be observed above

Fig. 1 Crack-like defect at centerline of hot-rolled product arising
due to centerline segregation
or below the mid thickness plane of the hot-rolled products
or sometimes in both directions, as shown in Fig. 5.
Sometimes they are present in addition to centerline seg-
regation. The presence of segregation line at the center of
hot-rolled products is a well-studied phenomenon but
similar segregation line at off-center locations is not well
understood. However, the presence of segregations sug-
gests that the delamination at off-center locations is related
to some pre-existing internal defects in the continuously
cast slab.
The mushy zone is the region of a continuously cast
strand where the solid and liquid coexist as a mixture. In

Fig. 2 Crack-like defect at off-center location of hot-rolled plates observed after forming

Fig. 3 Photograph of
transverse section of rolled
product revealing segregation
band along the crack line at off-
center location after
macroetching (50 vol% HCL)

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Fig. 4 Optical micrographs
indicating the presence of
manganese sulfide stringers at
the off-center crack locations
Fig. 5 Transverse section of macroetched hot-rolled products show-
ing segregation band at centerline and (A) off-center location in one
direction (B) off-center location in both directions about the mid
thickness plane
Fig. 6 Sulfur print plate of transverse section of a cast slab showing
(A) intercolumnar cracks and (B) centerline segregation
the Brittle Temperature Range (Zero Strength Temperature
to Zero Ductile Temperature), this zone is characterized by
extremely low-critical strain to fracture [1]. When the
combined strain arising on the solidifying front due to
strand bulging, misaligned segment rolls, or uneven
solidification exceeds a critical strain, there are chances of
forming intercolumnar cracks [2–5]. Since the surrounding
of the cracks contains solute-rich interdendritic liquid,
there are possibilities of the cracks to get filled with the
segregated liquid. However, at some locations having
heavy interdendritic bonding, the flow of fluid may be
blocked and the cracks may remain open and unfilled [1].
97
The susceptibility toward forming intercolumnar cracks
during solidification depends majorly on the extent of
Brittle Temperature Range. Segregating elements like
sulfur and phosphorus lower solidification temperature of
steel below its equilibrium solidus, thereby enhancing this
range [1]. In this perspective, high-carbon steels are more
prone to cracking as compared to low-carbon steels
because of their larger solidification range (Tsolidus Tliq-
uidus). Also segregation tendencies of sulfur and phosphorus
are higher when solidification occurs in austenitic mode as
in case of high-carbon steels [6].
Sulfur printing (S-print) of transverse section of cast
slab is a common technique to evaluate its internal quality.
This technique is generally used to judge the severity of
centerline segregation and intercolumnar cracks in slabs.
Figure 6 shows the photograph of a typical sulfur print
plate of a slab having centerline segregation and inter-
columnar cracks. Intercolumnar cracks are observed at the
off-center locations of the slabs. Various literatures also
report possibilities of them to be filled with solute-enriched
segregated liquid. Therefore, question arises whether these
cracks are related to the off-center segregation line in
rolled products.
Several authors have studied the origin and formation of
internal defects like centerline segregation and inter-
columnar cracks in continuously cast slabs. Effect of
centerline segregation in cast slabs on the internal quality of
the hot-rolled products is also well known [6, 7]. However,
the effect of the intercolumnar cracks in slabs on the
internal quality of hot-rolled product is an area which has
not been significantly explored before. There is a general
conception that the internal cracks get welded during hot-
rolling operation. This may be true for crack portions
remaining open in slab and free from segregations. How-
ever, whether the same is applicable to crack portions filled
with segregated liquid is a question. Through systematic
laboratory experimentations, the present work is aimed to
establish a strong correlation between intercolumnar cracks
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Table 1 Technical specification of CC#3 of LD2&SC shop of TATA

Steel Jamshedpur works
Caster specifications

Caster type Curved (bow type)

Mold type Curved
Ladle capacity 165 T
Tundish design Step type tundish
Tundish capacity 35 T
SEN design 15° double port (Slit SEN)
Mold length 900 mm
Number of segments 15
Bending radius 10 m Fig. 7 Schematic illustration of sampling location of slab block from
S-print slab sample
Bending/unbending Multi-point
Metallurgical length 30.5 m

Table 2 Continuous casting parameters of the slab under study

Casting parameters

Slab dimension 218 mm 9 1250 mm

Casting speed 0.9 m/min
Superheat 23 °C
Tundish weight 32 T
Primary cooling water (broad side) 4000 L/min
Primary cooling water (narrow side) 500 L/min
Secondary cooling water 1500 m3/h

in cast slab and off-center defects in hot-rolled plates or

strips.
Fig. 8 Sampling location of microsample from suspected crack
portion in the slab block

Experimental Procedure
Sample Collection
Various grades of steel produced in TATA Steel,
Jamshedpur require sound internal quality for precision
applications like automobile shockers, chain links, long
members, etc. Such grades have carbon content ranging
from 0.07 wt.% C to 0.55 wt.% C. Complaints regarding
off-center cracking were reported in most of these grades,
and the rejection rates were around 8%. One among such
grades having 0.55 wt.% carbon was randomly taken up for
the study.
A slab having composition of Fe-0.55C-0.75Mn-0.007S-
0.015P-0.21Si was selected, whose S-print plate indicated
the presence of intercolumnar cracks. The slab was cast in
CC#3 of LD2&SC shop in TATA Steel, Jamshedpur
works. The technical specification of this continuous caster
is shown in Table 1, and the continuous casting parameters
of the slab under study are listed in Table 2. According to
S-print plate, the cracks were present below the centerline
of the slab and extended between 30 and 50 mm from the
bottom surface (fixed side). The corresponding S-print slab
sample, separated off line from the tail end of the original
slab, was considered for our study to assess the impact of
intercolumnar cracks on rolled product quality. Due to the
absence of laboratory facilities to roll slab samples of full
thickness, a small block (60 mm 9 95 mm 9 75 mm) was
separated from the S-print sample (1250 mm 9 95 mm 9
215 mm) at the suspected location of intercolumnar cracks.
The sampling location of the slab block from the S-print
sample is schematically illustrated in Fig. 7. During sample
retrieval, precautions were taken to cause no damage to the
intercolumnar crack portion. Additionally, sampling was
such that centerline portion of the slab was avoided. This
would ensure that the slab block contained no defect other
than the intercolumnar cracks and an unbiased analysis of
their impact on the rolled product quality could be carried
out.

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Fig. 9 Sampling location from hot worked plate of 9-mm thickness
Fig. 10 Macroetched slab block revealing intercolumnar cracks.
(actual photograph)
Microscopic Analysis of the Intercolumnar Crack Portion
in the Slab
A microsample of dimension 10 mm 9 10 mm 9 10 mm
was separated from the suspected location of intercolumnar
cracks in the slab block. The schematic illustration of its
sampling location is represented in Fig. 8. The collected
microsample was hot mounted, polished, and observed
under optical microscope (Lieca, model: DMRX, Ger-
many) in unetched condition. Following this, studies were
made under FE-SEM (Model: Ziess, Vorpommern, Ger-
many) with EDAX and X-ray mapping attachments.
Macroetching
The transverse and longitudinal faces of the slab block
(50 mm 9 95 mm 9 75 mm) were prepared using Vertical
99
Fig. 11 Schematic diagram of macroetched slab block
Fig. 12 Unetched slab sample showing the presence of globular
inclusions near the crack (9500 magnification)
milling machine (Model: VF-1). The prepared sample was
then macroetched according to ASTM E340-13 standard.
The block was completely immersed for 2 h in a freshly
prepared HCl solution (1:1 by volume) maintained at a
temperature of 70 °C. After proper cleaning and drying, the
block was examined for the presence of intercolumnar
cracks.
Hot Working of the Slab Sample to a Plate of 9-mm
Thickness
The slab block containing the intercolumnar cracks was
reheated to a temperature of 1220 °C in electric trolley
furnace and soaked for 1 h. The sample was then hot
worked using laboratory facility to a plate of 9-mm
thickness, through multiple passes.
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Fig. 13 X-ray mapping

revealing manganese and sulfur
in globular inclusion

Fig. 14 EDS line scan across the crack indicating MnS both inside as well as in the vicinity of the intercolumnar crack

Macroetching of the Transverse Section of the Hot prepared, macroetched, and investigated for the presence of
Worked Plate any defects.

In order to examine its internal quality, a sample was Microscopic Analysis of the Hot Worked Plate
retrieved from the hot worked plate as indicated schemat-
ically in Fig. 9 using hydraulic shear machine (Model: A microsample was separated from the defect portion of
HVR 2020). The transverse face of the cut out sample was the macroetched hot worked plate sample. In order to

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Fig. 15 Defects in hot worked plate sample arising from intercolum-
nar cracks in the slab sample
Fig. 16 Unetched hot worked plate sample showing MnS stringers at
the defect location (9500 magnification)
identify the exact nature of the defect, optical microscopic
investigation was carried out on the polished microsample
in unetched and etched (2 wt.% nital) condition. The
sample was then subjected to SEM-EDX analysis using
FE-SEM (Model: Ziess, Vorpommern, Germany) with
EDAX and X-ray mapping attachments.
Results and Discussions
Investigation of Intercolumnar Crack in Slab
Macroetching of the slab block revealed the internal cracks
from the original slab. These cracks are observed perpen-
dicular to the casting direction and at several locations in
the transverse faces of the slab block as shown in Fig. 10.
All the cracks are at same distance with respect to the
bottom surface of the slab as noted from the schematic
diagram of the macroetched slab block in Fig. 11. Since
these cracks are generated at the solidification front, the
distance (‘s’) of the cracks from the adjacent slab surface
may be employed in solidification equation, d = v(s/k)2
(where s-shell thickness (mm); k-machine constant (mm/
min2); v-casting speed (mm/m); and d-distance from
101
meniscus (mm)) to roughly estimate the location in the
caster where the cracks would have formed. For the slab
under study, this distance (‘d’) is obtained to be 6640 mm
(putting s = 50 mm, v = 1100 mm/min, and
k = 20.35 mm/m), which corresponds to 9th segment of
the caster which was observed with misaligned guide rolls.
Misaligned rolls may result in deformation of the solid
shell due to bulging of strand between support rolls,
imposing strain on the solidification front leading to
internal cracks [2]. It may therefore be understood that
even the interior of the slab block would contain similar
cracks along the plane of cracks revealed on the surface of
the slab block.
The unetched microsample as observed under optical
microscope is shown in Fig. 12. It reveals the presence of
globular inclusions in the vicinity of an intercolumnar
crack. X-ray elemental mapping identifies the globular
inclusions to be of manganese sulfide origin as shown in
Fig. 13. SEM-EDS line scan analysis was carried out
across the crack at multiple locations and the manganese
sulfide-type inclusions are indicated inside the crack as
well. One such location may be noted from Fig. 14. It may
be understood that as intercolumnar cracks formed in the
mushy zone during casting, it world have created a suction
of solute-rich liquid from the neighboring interdendritic
spaces to fill the cracks. This resulted in accumulation of
solute elements like sulfur at certain locations inside and in
the surroundings of the crack. Consequently, it led to the
formation of inclusions observed in association with the
intercolumnar cracks.
Investigation of Defect in the Hot Worked Plate
On macroetching, the transverse face of the hot worked
plate sample reveals a segregation band (defect line) as
shown in Fig. 15. This resembles with observation of
centerline segregation in macroetched hot-rolled plate
samples. Also, the segregation band is similar to that found
associated with off-center crack locations in defect com-
ponent as shown in Figs. 3 and 4. Optical microscopy in
unetched condition reveals plenty of fine stringers at the
segregation band location as shown in Fig. 16. Using EDS
point analysis, the stringers are confirmed to be of man-
ganese sulfide type as represented in Fig. 17.
The manganese sulfide stringers in the rolled plate
originate from the globular sulfide inclusions observed in
association with the intercolumnar crack in the slab. The
presence of stringers at the defect location in plate suggests
that the segregations inside and around the intercolumnar
cracks do not disappear on rolling. Rather, they accumulate
along some plane in the rolled product, forming a segre-
gation band. The location of this segregation band with
respect to the thickness direction of the rolled plate is
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Fig. 17 EDS analysis confirming the presence of MnS stringers at defect portion in hot worked plate
Fig. 18 Transverse section of rolled plate showing both centerline
defect band (A) and off-center defect band (B)
dependent on the location of the intercolumnar cracks with
respect to the transverse direction of the slab. During cold-
forming operations, delamination or cracking may occur
along this plane containing heavy concentration of segre-
gates and inclusions.
A slab having both centerline segregation and inter-
columnar cracks is suspected to create multiple defect
bands in the transverse section of the hot-rolled products as
shown in Fig. 18. In that case, the segregation band
developed due to intercolumnar cracks would be away
from the centerline of the hot-rolled product. As there is no
facility to experimentally roll full thickness slab samples,
investigation of hot-rolled plate samples collected from a
rolling mill may validate above hypothesis.
Another slab block was sampled that did not contain any
intercolumnar cracks. This slab block was then rolled in a
similar procedure as the block containing intercolumnar
cracks. The transverse section of the corresponding hot
worked plate was macroetched and no segregation band
(defect line) was revealed, as shown in Fig. 19. This
indicates that slab blocks that do not contain intercolumnar
defects do not form the type of off-center cracking
observed above and supports the effect of intercolumnar
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J Fail. Anal. and Preven. (2016) 16:95–103
Fig. 19 Defect-free hot worked plate obtained from slab sample
without intercolumnar crack
cracks on the formation of defect lines (cracking) in hot-
rolled products.
Recommended Actions to Reduce Off-Center Cracking
From this experimental study, a strong correlation is seen
to exist between the intercolumnar crack in slabs and off-
center defect in hot-rolled strips. Thus, any countermeasure
taken to reduce occurrence of intercolumnar cracks is
likely to reduce generation of off-center defects in the
rolled products.
Sulfur content of steel plays a crucial role in the gen-
eration of intercolumnar cracks. It is recommended to
lower sulfur levels in steel to avoid intercolumnar cracks in
slabs and thereby off-center defects in rolled products. In
TATA Steel, the sulfur content is restricted to 0.005% for
all grades facing off-center cracking at customer end dur-
ing forming applications. Secondly, casting parameters like
superheat and casting speed are similarly optimized to
reduce crack occurrences in slabs. Casting speed is
restricted to 1 m/min and superheat is maintained in the
range of 15–25 °C. Thirdly, misaligned segment rolls in
caster increase propensity for developing intercolumnar
cracks. Therefore, it is recommended to cast the critical
grades only after roll gaps and alignments in the caster
segments are properly checked. Also, for these grades, no
coils are sent to customers if its corresponding slab
revealed intercolumnar cracks during S-printing.
J Fail. Anal. and Preven. (2016) 16:95–103
Intercolumnar cracks are not specific to any particular
grade. Therefore, chances of observing off-center defects
span all grades. Similarly, recommendations for preventing
off-center cracking apply to all grades. High-carbon grades
are more prone to cracking and therefore forming off-
center defects because of reasons already discussed.
Implementing the aforesaid actions has reduced rejection
rates at customer end from 8% in FY’13 to 0.3% in FY’15.
Conclusions
Following conclusions may be drawn from the present
study:
(1) Intercolumnar cracks lead to off-center segregation
bands in rolled products which may result in
delamination or cracking during forming operations.
(2) Reduction of the occurrences of intercolumnar
cracks reduces chances of off-center cracking.
(3) The occurrence of off-center cracking can be
reduced by (a) reducing the sulfur content of the
steel (b) properly checking the roller gaps and
alignment of caster segments prior casting complaint
facing grades, and (c) ensuring that coils rolled from
slabs containing intercolumnar cracks do not reach
customers.
103
Acknowledgments The authors wish to thank colleagues from Tata
Steel Ltd for their support and encouragement in completion of the
work. Help received from National Metallurgical Laboratory,
Jamshedpur for carrying out experiments using their laboratory
facilities is also appreciated.
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